Mercury SKI User manual

90-860178001 APRIL 2000 Printed in U.S.A. - 2000, Mercury Marine Page 1 of 48
The following are registered trademarks of
Brunswick Corporation: Merc, MerCathode,
MerCruiser, Mercury, Mercury Marine,
Quicksilver, and Ride-Guide.
GASOLINE ENGINES SKI MODELS
NOTICE to INSTALLER
After Completing Installation, These Instructions Should Be Placed With The Product For The Own-
er’s Future Use.
NOTICE to COMMISSIONING DEALER
Predelivery Preparation Instructions Must Be Performed Before Delivering Boat To The Product
Owner.
Table of Contents
General Information 3. . . . . . . . . . . . . . . . . . . . . . .
Notice to Boat Manufacturer/Installer 3. . . . . . .
Quicksilver Products 4. . . . . . . . . . . . . . . . . . . . .
Installation Products 4. . . . . . . . . . . . . . . . . . . . .
Torque Specifications 4. . . . . . . . . . . . . . . . . . . .
Serial Number Decal Placement 4. . . . . . . . . . .
Fuel Octane Requirements Sticker 4. . . . . . . . .
Engine Rotation 4. . . . . . . . . . . . . . . . . . . . . . . . .
Transmission 5. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Requirements 6. . . . . . . . . . . . . . . . .
Boat Construction 6. . . . . . . . . . . . . . . . . . . . . . .
Exhaust System 9. . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Delivery System 10. . . . . . . . . . . . . . . . . . .
Battery 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Cables 13. . . . . . . . . . . . . . . . . . . . . . . . .
EFI Electrical System Precautions 14. . . . . . . .
Instrumentation 14. . . . . . . . . . . . . . . . . . . . . . . . .
Propeller Selection 15. . . . . . . . . . . . . . . . . . . . . .
Throttle/Shift Remote Control and
Cables 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Seawater Connections - General
Information 17. . . . . . . . . . . . . . . . . . . . . . . . . . .
Hot Water Heater Installation Information 18. .
Engine Installation 19. . . . . . . . . . . . . . . . . . . . . . .
Battery Cable Connection 19. . . . . . . . . . . . . . . .
Engine Mount Pre-Adjustment 20. . . . . . . . . . . .
Initial Engine Alignment 22. . . . . . . . . . . . . . . . .
Final Engine Alignment 22. . . . . . . . . . . . . . . . . .
Seawater Pickup Pump Connection 24. . . . . . .
Throttle/Shift Cable 25. . . . . . . . . . . . . . . . . . . . .
Fuel Supply Connection 29. . . . . . . . . . . . . . . . .
Audio Warning System 33. . . . . . . . . . . . . . . . . .
Electrical Connections 31. . . . . . . . . . . . . . . . . . .
Exhaust System Hoses/Tubes
Connection 31. . . . . . . . . . . . . . . . . . . . . . . . . . .
Predelivery Preparation 32. . . . . . . . . . . . . . . . . . .
Battery Connection 32. . . . . . . . . . . . . . . . . . . . .
Test Running Engine 32. . . . . . . . . . . . . . . . . . . .
Boat-In-The-Water Tests 32. . . . . . . . . . . . . . . . .
Cold Weather or Extended Storage
Draining Instructions 33. . . . . . . . . . . . . . . . . . .
Quicksilver Instrumentation Wiring
Diagrams 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MIE Gasoline Engine Wiring Diagrams 42. . . . .
MIE Water Flow Diagram 47. . . . . . . . . . . . . . . . . .
Predelivery Inspection 48. . . . . . . . . . . . . . . . . . . .

GASOLINE ENGINES SKI MODELS
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THIS PAGE IS INTENTIONALLY BLANK

GASOLINE ENGINES SKI MODELS
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General Information
Notice to Boat Manufacturer/Installer
Throughout this publication, “Warnings” and “Cautions” (accompanied by the International
Hazard Symbol !) are used to alert the manufacturer / installer to special instructions
concerning a particular service or operation that may be hazardous if performed incorrectly
or carelessly –– Observe Them Carefully!
These “Safety Alerts,” alone, cannot eliminate the hazards that they signal. Strict com-
pliance to these special instructions when performing the service, plus “common sense” op-
eration, are major accident prevention measures.
WARNING
Hazards or unsafe practices which COULD result in severe personal injury or death.
CAUTION
Hazards or unsafe practices which could result in minor personal injury or product
or property damage.
IMPORTANT: Indicates information or instructions that are necessary for proper in-
stallation and/or operation.
This installation requirements manual has been written and published by Mercury Marine
to aid the boat manufacturer involved in the application and installation of the products de-
scribed herein.
It is assumed that these personnel are familiar with marine product application and the
installation procedures of these products, or like or similar products manufactured and mar-
keted by Mercury Marine. Furthermore, it is assumed that they are familiar with, if not trained
in, the recommended installation procedures of these products.
It is the responsibility of the OEM to select the appropriate engine/transom/drive package
(including the correct gear ratio and propeller) for a given boat. Making an appropriate selec-
tion requires knowledge of the boat (weight, length, hull design, intended use and duty cycle,
desired speed, etc.) that is uniquely in the possession of the OEM. While Mercury employs
people capable of assisting the OEM on such issues, the final decision rests with the OEM.
Mercury recommends that any new or unique hull/power package combination be thor-
oughly water tested prior to sale, to verify (among other things) that the boat performs as
desired, and that the engine runs in the appropriate rpm range.
We could not possibly know of and advise the marine trade of all conceivable applications
and installations which might be achieved, and of the possible hazards and/or results of
each conceivable application or installation. We have not undertaken any such wide evalua-
tion. Therefore, any manufacturer which, or person who, applies or installs the product in
a manner which does not fulfil the requirements listed herein, first must completely satisfy
themselves that neither their safety nor the product will be endangered by the application
or installation procedure selected.
It is recommended that a Mercury Marine Field Product Engineer be contacted for assis-
tance if specific application or installation problems are encountered.
All information, illustrations, and specifications contained in this manual are based on the
latest product information available at time of publication. As required, revisions to this man-
ual will be sent to all OEM boat companies.

GASOLINE ENGINES SKI MODELS
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Quicksilver Products
Quicksilver gauges, remote controls, steering systems, propeller shaft couplers, etc. are
available for this product. Refer to “Quicksilver Accessories Guide”for complete listing.
This “Guide”is available from:
Attn: Parts Department
Mercury Marine
W6250 W. Pioneer Road
P.O. Box 1939
Fond du Lac, WI 54936-1939
Installation Products
Quicksilver 2-4-C
Marine Lubricant with Teflon 92-825407A3
Quicksilver Liquid Neoprene 92-25711-2
Quicksilver Perfect Seal 92-34227-1
Torque Specifications
DESCRIPTION lb. in. lb. ft. N·m
Engine Mount Bracket Screw 48 65
Trunnion Clamping Screw and Nut 50 68
Propeller Shaft Coupling Screw and Nut 50 68
Exhaust Manifold Screw 20 27
Fuel Line Inlet Fitting See Note.
Note: Refer to Fuel Delivery System - “Special Information For All Gasoline Engines.”
Serial Number Decal Placement
There are three engine serial number decal strips provided with each power package. One
should be used for each of the following:
•Engine Specification Decal
•Warranty Registration Card
•Operation, Maintenance and Warranty Manual identification page.
Engine Rotation
Engine rotation is described when observed from the rear of the engine (transmission end)
looking forward (water pump end).
Engine rotation is indicated on engine specifications and serial number decal.

GASOLINE ENGINES SKI MODELS
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Transmission
IDENTIFICATION
Velvet Drive Transmissions
On Velvet Drive In-Line Transmissions the gear ratio (in forward gear) is marked on trans-
mission identification plate. Transmission output shaft rotation and propeller rotation re-
quired (in forward gear) is indicated on a decal on transmission case. Transmission rotation
is described when viewed from the rear of transmission.
22556
a
b
c
a-Transmission Identification Plate
b-Gear Ratio (in Forward Gear)
c-Output Flange Rotation Decal (in Forward Gear)
Propeller Rotation
Propeller rotation is not necessarily the same as engine rotation. Refer to the appropriate
following information and drawings for specific information.
IMPORTANT: Use of proper rotation propeller (specified on transmission output
flange rotation decal) is critical since the transmission must be operated in forward
gear selector position only to drive boat forward. If the wrong rotation propeller is
installed and transmission is operated in reverse to propel the boat forward, trans-
mission failure WILL occur.
On engines which are equipped with Velvet Drive in-line, a LH propeller is required.

GASOLINE ENGINES SKI MODELS
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ENGINE/PROPELLER SHAFT INSTALLATION ANGLE
The transmission and engine should be mounted so that the angle relative to horizontal is
as shown in the installation drawings. Refer to individual installation drawings for each spe-
cific engine and transmission.
Relative to horizontal, never install the engine with the front (pulley end) down.
IMPORTANT: On all engines, a high angle of installation [front (pulley end) of engine
up] along with low transmission oil levels can permit transmission pump cavitation
on some models when operating in rough water.
COUPLING
The coupling is a flange type coupler (available through Quicksilver Accessories). All cou-
pler bolts must be SAE Grade 8 (Metric Grade 10.9) or better, with a shoulder (grip length)
long enough to pass through the face mating plane of couplers. All coupler bolts must be
torqued to 50 lb. ft. (68 N·m).
PROPELLER SHAFT DIAMETER
Propeller shaft diameter should be of sufficient size for the type of application.
Installation Requirements
Boat Construction
ENGINE BED
Distance between starboard and port engine mount is 22-1/2 in. (572 mm). Engine bed must
position engine so that a minimum of 1/4 in. (6 mm) up and down adjustment still exists on
all 4 mounts after performing final engine alignment. This is necessary to allow for realigning
engine in the future.
NOTE: Although the engine mounts allow some adjustment, it is a good practice to ensure
that the front and rear mount locations in the vessel are in parallel planes. This may be
checked by tying a string from the left front mount location to the right rear mount location
and another from right front to left rear. The strings should touch where they cross.
ENGINE COMPARTMENT
WARNING
Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be ad-
hered to when constructing the engine compartment.
Care must be exercised in the design and construction of the engine compartment. Seams
must be located so that any rain water that may leak through the seams is directed away
from the air intake system. Water that runs onto the air intake may enter the engine and
cause serious damage to internal engine parts.

GASOLINE ENGINES SKI MODELS
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Over the last several years, engine compartments have been designed to be quieter. The
most common material used to deaden the engine sound is some type of insulation material.
Normally, the quieter the engine compartment is, the more insulation material used, which
results in less air space inside. The less air space inside the engine compartment, the hotter
the inside air temperature. Attention must be given to the air temperature that is inside this
engine compartment while the engine is running or after a period of time after the engine
is shut off (heat soak). Refer to the following information on Engine Compartment
Ventilation.
ENGINE COMPARTMENT VENTILATION
General Information
According to Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations the en-
gine compartment ventilation system has multiple tasks. Included are the following:
1. To supply the engine with combustion air.
2. To maintain a low temperature in the engine compartment.
Fresh air should enter the engine compartment as low as possible and the heated air should
be discharged from the highest point.
When sufficient ventilation is not provided, too much heat can build-up inside of engine
compartment and cause vapor locking. The engine will not want to restart after it has been
shut off for a short period of time. If it does restart, the engine will quit when given the throttle
to get the boat up on plane or to pull up a water skier.
For engines utilizing fuels containing alcohol and the newer “reformulated gasolines”(See
OEM Service Bulletin 95-2), proper ventilation is more critical to prevent vapor locking.
If a separate air shaft (or similar) is used to provide engine compartment ventilation or addi-
tional ventilation, care must be taken to prevent seawater and spray from entering it.
Combustion Air Requirements
Engine compartments with natural draft ventilation must have vent openings of sufficient
size and location to accomplish the tasks previously outlined.
IMPORTANT: The size of ventilation openings must be increased if any auxiliary
equipment is located in the engine compartment.
The combustion air requirement (per engine) for the specified engines at Wide Open
Throttle are given in the chart below:
Engine Air Flow Requirements (Per Engine)
Model Engine Air Requirements at
Wide Open Throttle Physical Volume
5.7L 486 ft.3/Min.
(0.229 m3/sec.) 5.3 ft.3
(150 L)
350 Mag MPI 506 ft.3/Min.
(0.239 m3/sec.) 5.3 ft.3
(150 L)
MX 6.2L MPI 568 ft3/Min.
(0.268 m3/sec.) 5.3 ft.3
(150 L)
Black Scorpion 527 ft.3/Min.
(0.249 m3/sec.) 5.3 ft.3
(150 L)
In addition, the pressure differential (outside engine compartment versus inside engine
compartment) should not exceed 2 in. (51mm) of water (measured with a manometer) at
Wide Open Throttle.

GASOLINE ENGINES SKI MODELS
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Compartment Temperature - Specifications
Air temperatures inside of engine compartments have been measured in excess of 200°F
(82°C). The long term effect to fuel system components running at these excessive temper-
atures is not known at this time.
According to specification SAE J1223 for Marine Carburetors:
“The carburetor shall be capable of operation throughout an ambient (air temperature)
range from +20°to +176°F (–7°to +80°C) without failure.”
Carburetors, throttle body injection (TBI) units and components for multi-port EFI systems
used by MerCruiser meet this specification.
Under the hottest outside air temperature condition at which the boat will be operated, the
air temperature inside the engine compartment, measured at the flame arrestor, shall not
exceed 176°F (80°C). Also, the temperature of the fuel being supplied to the engine shall
not exceed 110°F (43°C) at any location between the fuel tank and the engine’s fuel pump.
Since many factors influence engine compartment temperature, temperature measure-
ments should always be carried out as follows.
Compartment Temperature - Testing
Test as follows:
1. The boat being tested shall be a standard production boat fitted as it would be for
delivery to a dealer.
2. Temperature test meter used shall be of the type that can be read without opening the
engine cover.
3. During the test, in Step 4, engine compartments are to remain closed. No outside air is
to be forced into the engine compartment during the test and the bilge blower should not
be running.
4. Engine Running and Heat Soak Test:
a. Use 1 meter and 2 thermal couples. Place one thermal couple at the flame arrestor
to measure the inlet air temperature. Place the second thermal couple at the fuel
pump to measure the inlet fuel temperature. A third thermal couple is needed if the
fuel supply line between the tank and the fuel pump is higher than the fuel pump.
Place the third thermal couple at the highest point of the supply line to measure the
temperature of the fuel at that point.
b. Start engine to warm it up. After engine is at its normal operating temperature, run
engine at 1500 rpm (in neutral gear) for 15 minutes. Record both temperature read-
ings at 5 minute intervals.
c. After 15 minutes running at 1500 rpm, shut engine off and continue to record both
temperature readings at 5 minute intervals for the next 45 minutes.
d. After the 45 minute heat soak test, start engine and idle (in neutral gear) for 20 min-
utes. Continue to record both temperature readings at 5 minute intervals.
IMPORTANT: If the temperature at either location exceeds specifications, the engine
compartment will need additional ventilation until both temperatures remain below
these specifications.

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Exhaust System
IMPORTANT: It is the responsibility of the boat manufacturer, or installing dealer, to
properly locate the engine and install the exhaust system. Improper installation may
allow water to enter the exhaust manifolds and combustion chambers and severely
damage the engine. Damage caused by water in the engine will not be covered by
MerCruiser Warranty unless this damage is the result of defective part(s).
Determine if exhaust elbow risers are required by taking measurements “a”and “b”with boat
at rest in the water and maximum load aboard. Subtract (b) from (a) to find (c). If (c) is less
than specified in chart, select appropriate size exhaust elbow riser kit, and exhaust exten-
sion kit if applicable, that will correctly position exhaust elbow.
Model (c) = (a) Minus (b)
All Models (c) Must Be 13 in.
(330 mm) or More
22457
b
c
da
Typical Installation Shown
a-From Waterline To Top Of Transom
b-From Highest Point On Exhaust Elbow To Top Of Transom
c-Equals (a) Minus (b)
d-Waterline At (c) Rest
•System must not cause excessive back pressure when measured at exhaust elbow out-
lets. Back pressure MUST NOT exceed 2 psi (14 kPa). Minimum exhaust hose sizes
are given in chart:
Minimum Exhaust Outlet Hose Size
3-1/2 in. (88.9 mm)
•Exhaust hoses must be secured at each connection with two (2) hose clamps.
•Exhaust hoses must be connected to exhaust elbows so that they do not restrict the flow
of discharge water from the elbow. If hoses are connected incorrectly, a hot spot in the
hose can occur and can eventually burn through.
NOTE: A kit is available, when applicable, to reduce from the 4 in. (102 mm) to 3 in. (76 mm).
Refer to the “Quicksilver Accessories Guide” for kit part number.

GASOLINE ENGINES SKI MODELS
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Fuel Delivery System
WARNING
Boating standards (NMMA, ABYC, etc.) and Coast Guard regulations must be ad-
hered to when installing fuel delivery system.
GENERAL
The main concern of a boat’s fuel system is safety; this must be achieved through a techni-
cally sound installation and constant inspection.
The fuel system, from the filler pipe to the fuel pump, is the same in principle for all boats.
The fuel tank is an integrated component of the boat. Refer to the special information on
service and maintenance that you have received from the tank manufacturer.
NOTE: On Ski Boat Applications: If during testing for a particular application, you experi-
ence fuel starvation in sharp high speed turns, baffles or a fuel sump may be needed in the
tank to help correct this condition.
Only a few points related to function and safety are listed here. Refer to boating standards
(NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines:
•All connections should be on the upper side of the tank.
•The drain plug at the lowest point on the tank serves to permit the removal of water and
sediment.
•The filler pipe outer diameter should be at least 2 in. (51 mm).
•The tank breather pipe must have an inner diameter of at least 1/2 in. (13 mm) and must
be fitted with a swan neck to prevent water from entering the tank.
It is recommended that the exact route and length of the fuel lines be established at the first
installation of the engine to prevent problems later in connecting them to the engine.
All fuel lines must be well secured. The holes where the lines run through the bulkheads
should be carefully rounded off or protected with rubber grommets. This prevents damage
to the lines from abrasion.

GASOLINE ENGINES SKI MODELS
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The following, but not limited to the following, additional fuel connection related points, ap-
plying to all engines unless otherwise stated, must be considered [Refer to boating stan-
dards (NMMA, ABYC, etc.) and Coast Guard regulations for complete guidelines]:
1. Fuel tank should be mounted below carburetor level (if possible) or gravity feed may
cause carburetor fuel inlet needle to unseat and flooding may result.
2. On Gasoline Engines: The maximum measured vacuum at the engine’s fuel inlet must
not exceed 2 in. Hg (6.9 kPa) at idle rpm, 3000, full throttle rpm, and back at idle rpm.
IMPORTANT: Vacuum reading higher than specified can cause vapor locking with
some of today’s fuels. It can also cause poor engine performance because of fuel
starvation.
3. Fuel pickup should be at least 1 in. (25mm) from the bottom of fuel tank to prevent pick-
ing up impurities.
4. Fuel lines used must be Coast Guard approved (USCG Type A1).
Diameter of fittings and lines must not be smaller than 5/16 in. (8 mm) I.D. on 350 cid / 5.7L
and Black Scorpion engines.
Diameter of fittings and lines must not be smaller than 3/8 in. (10 mm) I.D. on 377 cid / 6.2L
engines.
5. Larger diameter (than previously specified) lines and fittings must be used on installa-
tions requiring long lines or numerous fittings.
6. Fuel line(s) should be installed free of stress and firmly secured to prevent vibration and/
or chafing.
7. Sharp bends in fuel lines should be avoided.
8. A flexible fuel line must be used to connect fuel supply line to fuel inlet fitting on engine
to absorb deflection when engine is running.
SPECIAL INFORMATION ABOUT ELECTRIC FUEL PUMPS
CAUTION
The electric fuel pump and factory installed water separating fuel filter have been
carefully designed to function properly together. Do not install additional fuel filters
and/or water separating fuel filters between fuel tank and engine.
The installation of additional filters may cause:
•Fuel Vapor Locking
•Difficult Warm-Starting
•Piston Detonation Due to Lean Fuel Mixture
•Poor Driveability

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SPECIAL INFORMATION FOR ALL GASOLINE ENGINES
WARNING
Avoid gasoline fire or explosion. Improper installation of brass fittings or plugs into
fuel pump or fuel filter base can crack casting and/or cause a fuel leak.
IMPORTANT: The following information is provided to ensure proper installation of
brass fittings or plugs installed into fuel pump or fuel filter base:
•Use #592 Loctite Pipe Sealant with Teflon on threads of brass fittings or plugs. DO
NOT USE TEFLON TAPE.
•Brass fittings or plugs should first be threaded into fuel pump or fuel filter base
until finger tight.
•Fittings or plugs should then be tightened an additional 1-3/4 to 2-1/4 turns using
a wrench. DO NOT OVERTIGHTEN.
•To prevent overtightening when installing a fuel line, the brass fittings should be
held with a suitable wrench as fuel line connectors are tightened securely.

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Battery
IMPORTANT: Boating industry standards (BIA, ABYC, etc.), federal standards and
Coast Guard regulations must be adhered to when installing battery. Be sure battery
cable installation meets the pull test requirements and that positive battery terminal
is properly insulated in accordance with regulations.
IMPORTANT: Engine electrical system is negative (–) ground. It is recommended (re-
quired in some states) that battery be installed in an enclosed case. Refer to regula-
tions for your area.
Select a battery that meets all of the following specifications:
1. 12-volt marine type.
2. Tapered post connector or side terminal connectors. Do not use a battery with wing nut
connectors.
3. Reserve battery capacity rating of at least:
Engine
(cyl./type) cid (L) Minimum Required Cranking
Battery Size
V8 Carb 350 (5.7) 375 cca/475 mca/90 Ah
V8 MPI 350 (5.7)
and 377 (6.2) 550 cca/700 mca/120 Ah
Battery Cables
Select proper size positive (+) and negative (–) battery cables using chart. Battery should
be located as close to engine as possible.
IMPORTANT: Terminals must be soldered to cable ends to ensure good electrical
contact. Use electrical grade (resin flux) solder only. Do not use acid flux solder as
it may cause corrosion and a subsequent failure.
GASOLINE ENGINES
Cable Length Cable Gauge
Up to 3-1/2 ft (1.1m) 4 (25mm2)
3-1/2 - 6 ft (1.1-1.8m) 2 (35mm2)
6 - 7-1/2 ft (1.8-2.3m) 1 (50mm2)
7-1/2 - 9-1/2 ft (2.3-2.9m) 0 (50mm2)
9-1/2 - 12 ft (2.9-3.7m) 00 (70mm2)
12 - 15 ft (3.7-4.6m) 000 (95mm2)
15 - 19 ft (4.6-5.8m) 0000 (120mm2)

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EFI Electrical System Precautions
NOTE: All references to EFI models apply to all EFI and MPI engines.
CAUTION
Avoid damage to the EFI electrical system and components. Refer to the following
precautions when working on or around the EFI electrical harness or when adding
other electrical accessories:
•DO NOT tap accessories into engine harness.
•DO NOT puncture wires for testing (Probing).
•DO NOT reverse battery leads.
•DO NOT splice wires into harness.
•DO NOT attempt diagnostics without proper, approved Service Tools.
Instrumentation
CAUTION
If Quicksilver wiring harness is used and a fused accessory panel is to be installed
(40-amp current draw maximum), be sure to connect it as shown in wiring diagram.
Do not connect accessory panel at any other location as wires in wiring harness
may not be of sufficient size to handle current load.
We recommend the use of Quicksilver Instrumentation and Wiring harness(es). On dual sta-
tion applications, oil pressure and water temperature senders (on engine) must be changed.
Refer to “Quicksilver Accessories Guide”for selection.
The 4 basic gauges that must be used with the engine are:
•Tachometer
•Oil Pressure
•Water Temperature
•Voltmeter
Route instrumentation wiring harness back to engine, making sure that harness does not
rub or get pinched. If an extension harness is required, be sure to secure connection proper-
ly. Fasten harness(es) to boat at least every 18 in. (460mm), using appropriate fasteners.

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Propeller Selection
GENERAL INFORMATION
IMPORTANT: Installed propeller must allow engine to run at its specified maximum
wide-open-throttle revolutions per minute (rpm). Use an accurate service tachometer
to verify engine operating rpm.
It is the responsibility of the boat manufacturer and/or the selling dealer to equip the power
package with the correct propeller(s). Specified engine wide-open-throttle (WOT) and oper-
ating rpm range are listed in the “Operation, Maintenance and Warranty Manual”attached
to the engine.
Select a propeller that will allow the engine power package to operate at or near the top end
of the recommended wide-open-throttle operating rpm range with a normal load.
There is a change in rpm between propeller diameter or pitches that is generalized in the
following chart:
MIE Models Diameter or Pitch Change RPM Change
Gasoline 1 Inch 150
If full throttle operation is below the recommended range, the propeller must be changed
to prevent loss of performance and possible engine damage. On the other hand, operating
an engine above the recommended operating rpm range will cause higher than normal wear
and/or damage.
After initial propeller selection, the following common problems may require that the propel-
ler be changed to a lower pitch:
•Warmer weather and greater humidity cause an rpm loss.
•Operating in a higher elevation causes an rpm loss.
•Operating with increased load (additional passengers, pulling skiers, etc.).
For better acceleration, such as is needed for water skiing, use the next lower pitch propel-
ler. However, do not operate at full throttle when using the lower pitch propeller but not pull-
ing skiers.
Because of the many variables of boat design, only testing will determine the best propeller
for a particular application. Available propellers are listed in the “Quicksilver Accessories
Guide.”
See “BOAT-IN-THE-WATER TESTS, Maximum RPM Test”in the power package Installa-
tion Manual.

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SPECIAL INFORMATION FOR GASOLINE ENGINES
IMPORTANT: When selecting a propeller consider this additional information, if ap-
plicable:
The engines listed in the following chart are equipped with an rpm rev-limiter that is
set to an upper (or limited) rpm amount. This limit is slightly above the normal operat-
ing range of the engine and is designed to help prevent damage from excessive en-
gine rpm. Once the rpm drop into the recommended operating rpm range, normal en-
gine operation resumes.
Engine Rev-Limiter
Model Engine Recommended Operating
RPM Range
Rev-Limit
RPM
Setting
5.7L 4400-4800 4900
350 Mag MPI 4600-5000 5100
MX 6.2L 4800-5200 5350
Black Scorpion 4800-5200 5300
Throttle/Shift Remote Control and Cables
Shift control and shift cable MUST position transmission shift lever EXACTLY as stated in
the specific power package Installation Manual or transmission failure may occur. Damage
caused to transmission as a result of improper shift lever positioning will not be covered by
warranty.
To ensure proper shift and throttle operation, we recommend the use of a Quicksilver
remote control and cables. Refer to “Quicksilver Accessories Guide”for selection. However,
if a control other than Quicksilver is to be used, control must provide a shift cable travel
of 2-3/4 in. (70 mm).

GASOLINE ENGINES SKI MODELS
Page 17 of 48
Seawater Connections - General Information
SEAWATER PICKUP AND HOSE
IMPORTANT: DO NOT install water pickup directly in line with propeller as pickup
may create turbulence and allow air to flow into the “propeller slipstream.”This will
cause propeller ventilation and will adversely affect boat performance.
Water pickup must be large enough to permit sufficient water flow to engine seawater pickup
pump for adequate engine cooling. Pickup also must supply a positive head while underway.
Water pickup should be located as close to seawater pickup pump inlet as possible and in
an area where an uninterrupted, solid stream of water will flow past when boat is underway.
Water inlet hose connections must be made with wire reinforced hose of adequate wall
thickness to prevent it from collapsing from pump suction. Be sure to secure hose connec-
tions with hose clamps. Secure hose to prevent contact with any moving parts of the engine.
Select the proper hose from the following chart:
Seawater Pickup Hose Inner Diameter
Gasoline Engines 1-1/4 in. (32 mm)
SEACOCK SIZE
Seacock used must have an internal cross-sectional area equal to or greater than seawater
hose to prevent restricting water flow. A brass ball or gate valve is required. Select a proper
seacock based on the following chart:
Seacock Size
(Internal Cross-Sectional Area Equal to or Greater Than Size Shown)
Gasoline Engines 1-1/4 in. (32 mm)
Install the seacock in an area where it will be easily accessible and supported adequately
to prevent hose fatigue.
SEA STRAINER
Strainer used must be of sufficient size to ensure that an adequate supply of water will be
maintained for cooling engine. Select a properly rated seawater strainer based on the fol-
lowing chart:
Seawater Strainer Minimum Flow Rate 1
Gasoline Engines 30 (114)
1Amounts listed are in gallons per minute and (liters per minute).
The seawater strainer should be installed in an area where it will be easily accessible for
inspection and cleaning. The strainer should be installed in water inlet hose after the sea-
cock (water inlet valve) to allow operator to shut off water when cleaning strainer.

GASOLINE ENGINES SKI MODELS
Page 18 of 48
Hot Water Heater Installation Information
IMPORTANT: When connecting a cabin heater or hot water heater, certain require-
ments must be met, including, but not limited to the following:
•Supply hose (from engine to heater) and return hose (from heater to engine)
MUST NOT EXCEED 5/8 in. (16 mm) I.D. (inside diameter).
•Make heater connections ONLY at locations indicated in the following informa-
tion.
•Refer to manufacturers’instructions for complete installation information and
procedures.
IMPORTANT: Do not reposition engine temperature switch; it must remain where in-
stalled by factory.
CAUTION
On closed cooling models, heater must be mounted lower than the fill cap on the
heat exchanger. If the heater is higher than the fill cap on the heat exchanger and
some coolant is lost from system, an air pocket may form in the closed cooling sys-
tem. This can cause the engine to overheat.
SUPPLY HOSE CONNECTION
75473
a
All Engines - If Available
a-Location For Hot Water Supply (Install Bayonet Fitting Here)
71758
a
All Engines - Alternate Location
a-Location For Hot Water Supply (Install Bayonet Fitting Here)

GASOLINE ENGINES SKI MODELS
Page 19 of 48
RETURN HOSE CONNECTION
75480
a
a-Location for Hot Water Return (Install Bayonet Fitting Here)
Engine Installation
NOTICE to INSTALLER
Before Starting Installation, Read “General Information”and “Installation Require-
ments”completely.
Battery Cable Connection
IMPORTANT: Engine electrical system is negative (–) ground.
IMPORTANT: Before connecting battery cables, make sure that grounding stud and
starter solenoid terminal are free of paint or any other material that could cause a
poor electrical connection.
1. Connect negative (–) battery cable to grounding stud on flywheel housing. Tighten nut
securely.
72773
a
a-Negative (–) Battery Cable
2. Place rubber boot (shipped with engine) over end of positive (+) battery cable and con-
nect to 3/8 in. (10 mm) terminal on starter. Tighten nut securely.

GASOLINE ENGINES SKI MODELS
Page 20 of 48
3. Coat negative and positive battery connections with Liquid Neoprene. After Liquid Neo-
prene has dried, slide rubber boot over positive battery cable connection.
74171
bc
a
a-Negative (–) Battery Cable
b-Positive (+) Battery Cable
c-90 Amp System Fuse DO NOT Remove (EFI and MPI Models)
Engine Mount Pre-Adjustment
1. Remove hardware holding engine to shipping pallet. Attach a suitable sling to lifting eyes
on engine. Lift engine from pallet with an overhead hoist.
2. Remove “L”shaped shipping bracket from both rear (transmission) mounts. Retorque
mount bracket attaching screw to 48 lb. ft. (65 N·m).
IMPORTANT: Engine mounts must be adjusted, as explained in Steps 3 and 4, to cen-
ter mount adjustment and establish a uniform height on all mounts.
3. Ensure that distance from bottom of all 4 engine mounts (2 front, 2 rear) mount to bottom
of trunnion equals 2-5/8 in. + 1/16 in. (10 mm + 2 mm). If not, loosen mount locking nut
and turn adjusting nut in direction required to obtain proper dimension, then retighten
locking nut. Be sure to leave mount positioned so that slot is forward (d).